2024 03 28 FPP Alignment PTA RIL Patalganga Final-2
2024 03 28 FPP Alignment PTA RIL Patalganga Final-2
2024 03 28 FPP Alignment PTA RIL Patalganga Final-2
ANALYSIS REPORT
_____________________________________________________________________________________________
PLANT/LOCATION
RELIANCE INDUSTRIES LIMITED
PATALGANGA,RASAYANI (MH)
_____________________________________________________________________________________________
REALIZATION DATE
March 28th – March 31th, 2024
_____________________________________________________________________________________________
®
PREPARED BY-
Sr. Eng. EKBAL MULLA
Eng. ABHINAV V.
C O N T E N T S_________________________________________________________________________
Introduction……………………………………………………………………………………………………………………………….… 3
Convention………………………………………………………………………………………………………………………………….. 4
1. Alignment
The job has been awarded to Allan Smith Engineering to optimize mechanical loading
on Dryer mechanical components. (Dryer end seals, support rollers, thrust rollers, girth
gear etc.) The purpose also includes adjustments, repairs, modifications required to
ensure maximum availability of the Dryer.
Slope 2.00 %
Commissioning 2003
Major Recommendation:
1. Carry out dryer Alignment once in year.
2. Carry out inspection on the Dryer preferably. Once in 3 months
Inlet End
P2
Pinion
P1 Inlet Pier
Outlet Pier
0.00 mm 0.00 mm
OUTLET INLET
PLANT RELIANCE INDUSTRIES LIMITED MACHINE TAG N DRYER_PTA M14258 SHEET 1.1 of 7
PS5/230177053
LOCATION PATALGANGA,RASAYANI (MH) WORK ORDER N 31 MAR 2024
Date- 23.03.2024
ALIGNMENT - ELEVATION VIEW
10750
1.5 INLET
OUTLET
PLANT RELIANCE INDUSTRIES LIMITED MACHINE TAG N DRYER_PTA M14258 SHEET 1.2 of 7
2.05% 2.00%
OUTLET INLET
2.08% 2.02%
PLANT RELIANCE INDUSTRIES LIMITED MACHINE TAG N DRYER_PTA M14258 SHEET 1.3 of 7
PS5/230177053
LOCATION PATALGANGA,RASAYANI (MH) WORK ORDER N Date- 23.03.2024 31 MAR 2024
ALIGNMENT ROLLER SKEW POSITION
2.30 mm 1.0 mm
OUTLET INLET
0.35 mm 0.30 mm
PLANT RELIANCE INDUSTRIES LIMITED MACHINE TAG N DRYER PTA M14258 SHEET 1.4 of 7
PS5/230177053
LOCATION PATALGANGA, RASAYANI (MH) WORK ORDER N 31 MAR 2024
Date- 23.03.2024
TIRE - ROLLER DIAMETER
A D
B E
C F
OUTLET INLET
DIAMETER DIAMETER
PART PART
DOWNHILL MIDDLE UPHILL DOWNHILL MIDDLE UPHILL
A 760.0 760.0 760.0 D 760.0 760.0 760.0
B 3600.0 3600.0 3600.0 E 3600.0 3600.0 3600.0
C 760.0 760.0 760.0 F 760.0 760.0 760.0
(all Dimensions are in mm)
PLANT RELIANCE INDUSTRIES LIMITED MACHINE TAG N DRYER_PTA M14258 SHEET 1.5 of 7
PS5/230177053
LOCATION PATALGANGA,RASAYANI (MH) WORK ORDER N Date- 23.03.2024 31 MAR 2024
DIMENSIONS ROLLER ALIGNMENT
(Before Alignment)
OUTLET INLET
P2
2045.5 P1 2046.6 2045.6
2047.5
PLANT RELIANCE INDUSTRIES LIMITED MACHINE TAG N DRYER_PTA M14258 SHEET 1.6 of 7
PS5/230177053
LOCATION PATALGANGA,RASAYANI (MH) WORK ORDER N 31 MAR 2024
Date- 23.03.2024
TIRE ROLLER OFFSET
47.0 3.0 25.0 25.0
OUTLET INLET
PLANT RELIANCE INDUSTRIES LIMITED MACHINE TAG N DRYER PTA M14258 SHEET 1.7 of 7
PS5/230177053
LOCATION PATALGANGA, RASAYANI (MH) WORK ORDER N 31 MAR 2024
Date- 23.03.2024
OBSERVATION & RECOMMENDATION:
1. Discharge pier
1.1 Tyre and both support roller surfaces with minor pitting marks.
1.2 Tyre ID and chair pad OD between some dust particles are observed.
1.3 Migration is zero observed at the discharge pier.
1.4 Support roller bearing lubrication is oil.
2. Inlet pier
2.1 Tyre and both support roller surfaces with a minor pitting mark.
2.2 Tyre ID and chair pad OD between some dust particles are observed.
2.3 Migration is zero observed at the discharge pier.
4. Thrust roller
4.1 Both support roller surfaces with satisfaction.
4.2 Axial gap is 3.3 mm between both thrusts’ rollers.
Recommendation: -
1. Ensure lubrication supports the roller raceway continuously.
2. Ensure the migration value as per recommended OEM and continuous lubrication
between chair pad and tire ID.
3. Take care about the axial movement in the dryer.
0.5 mm
OUTLET INLET
PLANT RELIANCE INDUSTRIES LIMITED MACHINE TAG N DRYER_PTA M14258 SHEET 2.1 of 2
PS5/230177053
LOCATION PATALGANGA RASAYANI (MH) WORK ORDER N 31 MAR 2024
Date- 23.03.2024
ALIGNMENT - CORRECTION
(By Support Roller Adjustment)
. INLET
OUTLET
0.55 0.30
PLANT RELIANCE INDUSTRIES LIMITED MACHINE TAG N DRYER PTA M14258 SHEET 2.2 of 2
PS5/230177053
LOCATION PATALGANGA, RASAYANI (MH) WORK ORDER N Date- 23.03.2024
31 MAR 2024
3. APPENDIX
3.1 NOTES ON ALIGNMENT
3.2 PRINCIPLE OF F.P.P ALIGNMENT
3.3 ROLLER CENTER DISTANCE (BEFORE ALIGNMENT)
3.4 ALINMENT SHEET
3.5 VERTICAL CORRECTION
FLOATING POINT ALIGNMENT
Concept
Floating point alignment for two pier supported rotary unit is carried out in cold
condition, by taking direct measurements at the contact point of roller and tire.
The reference chosen is tire. These measurements data are then calculated
for misalignment.
First of all floating point of rollers is brought to same plane of known reference
slope. Skew is eliminated to keep center axis of rollers parallel to
cooler axis. Elevation of cooler is then calculated and rollers
positioned accordingly to achieve the required cooler slope. This will
ensure uniform load sharing on the rollers at the pier thus ensure proper
cooler alignment. Also measurement of rollers slope and correction
carried out to ensure whole system should work together and not against
one another.
Method
Two optical reference lines are set on either side of the unit. These lines are
parallel to each other and also, parallel to the line passing through base
frames center. Parallelism is ensured by measuring reference point diagonally.
Roller positions are determined in reference to these optical lines using laser
device (distometer).
misalignment
Reason of
3. ONE SUPPORT ROLLER MAY BE OVERLOADED COMPARED
TO ANOTHER ROLLER.
4. FLOATING POINT ALIGNMENT ENSURES UNIFORM LOADING
ON THE SUPPORT ROLLERS.
OUTLET INLET
P2 2046.9
2046.9 P1 2046.9 2046.9
PLANT RELIANCE INDUSTRIES LIMITED MACHINE TAG N DRYER PTA M14258 SHEET 3.3 of 1
PS5/230177053
LOCATION PATALGANGA, RASAYANI (MH) WORK ORDER N Date- 23.03.2024 31 MAR 2024
ALIGNMENT SHEET
Feed end
Discharge end
Alignment
Feed end Discharge end
Axial Lateral
inclination of floating plane
after kiln alignment
2.01% 0.00%
NOTE:
“Y” MM
“X” MM “X” MM
X = 1.732 * Y MM
(for included angle of support roller as 30 degree)
Question arise how to actuate the dryer axial movement? Method of dryer axial
movement depends upon dryer design parameters, whether dryer is designed for full
floatation or forced floatation.
Since most of the dryer now a days equipped with hydraulic thrusting mechanism, we will
be considering forced floatation. About full floatation we will be dealt some time in future –
for academic interest.
As the dryer has been designed with a slope for material movement, the inclination is
also responsible for moving the dryer toward discharge end.
In sponge iron plants normal practice observed is to control the axial movement using end
seals. This can be considered as a temporarily relief to control the axial movement. And, it is
not preferred to make this habit as a regular practice because of:
1. Faster wear of faceplate seal segments because of increased friction.
2. Higher resistance offered to turn the dryer.
3. Increased motor amperage.
4. Increased consumption of grease lubrication at slip seal.
Apart from above observation some more indirect influence of increased slip seal air pressure.
1. Higher required air pressure
2. Higher load on air compressors.
3. Faster wear on compressor components.
4. Cumulative power consumption – Higher.
Usually the pressure, hydraulic pump can create is in excess of 120 bar, if such a pressure not
handled properly may result in damaging some or other mechanical component of thrust roller.
(Like damaging thrust roller bearing, damaging thrust roller surface, deforming thrust
roller base plate and in extreme case knocking off thrust roller.)
The designed inclinations in dryer, made the cooler to travel axially toward downhill. In
order to control / check excessive cooler movement in either direction thrust rollers were
provided.
skewing of support roller
Hydraulic thrust device properly designed is adequately dimensioned and capable of absorbing
all the thrust from the dryer. This allows support roller to positioned almost parallel and thus
wear on roller surface can be minimized and longevity increased. However practically it is
customary to absorb around 70 % axial load on thrust roller and balance 30 % on support
roller. Thus, we can conclude that each roller is sharing around 7.5 % of total dryer axial load.
Variation of dryer axial load 7.45 % to 7.55 % or close is responsible for dryer axial movement.
Note: - Recent trend (since last 15-20 years) is to design dryer as non-floating dryer. These dryer are also
observedrunning satisfactorily, since installed.
Maintenance problems begin when load bearing surface (support roller / tyre) of rotary
dryer start to show sign of wear. The wear on support roller may be in the form of spalls,
galling, step, taper or concave. Usually galling, spalls are indicative of initial wear,
where as step, taper, concave wear is observed in advanced stage. Any of the above
wears will lead to premature ageing of rotary components. Normally these observations
are labeled as casting defects, manufacturing defects or material defects and usually the
manufacturer is hold responsible.
Also, very common sight on support roller of sponge iron dryer is circular line,
markings. Again, it is considered as casting defects / material defects and
manufacturer is hold responsible. However the problem lies to the most common cause
of mechanical failure in process industry – lack of lubrication. Insufficient lubrication
result in increased wear because of lubrication starvation. The situation worsens by
dust reaching pinch point (between tire and roller) and accelerated wear is imminent.
Plant technician uses oil on support roller because of some or other reason. Micro cracks if
exists on rolling surface, oil act as an incompressible liquid, causes further deepening the
cracks and finally lead to spalls. Also, liquid lubricant holds suspended dust, aggravating
the wear of rolling components.
Recommended lubricant for support roller is dry graphite. Graphite is best suited for
support roller lubrication and is effective even at high temperatures, up to 550ºC. Further,
the advantages are:
Good and clean lubrication
Suitable for extreme pressure
Resistance to water, etc
figure a
Graphite has a sheet like structure where
the atoms lie in a plane and are only
weakly bonded to the graphite sheets
above and below. It is the weakly bonded
sheets that slide by each other to yield the
slipperiness or softness.
Graphite block is provided on support roller surface, preferably at clock position 11 (as
shown in figure b). The rolling movement of roller consistently transfers graphite film to pinch
point. Graphite film thus adheres to the surface for lubrication under extreme pressure,
temperature, and weather. Good lubrication ensured even in dusty environments and the
functional surfaces showed minimal wear.
There are different grades of graphite blocks available in market. Good block having a
smooth surface of high-grade graphite.
Allan Smith Engineering Pvt. Ltd.
Graphite is characterized in two groups: Natural and Synthetic.
Natural graphite is derived from mines. The quality of natural graphite varies with ore
quality and post mining process. The end product is graphite with carbon (high grade
graphite 96-98% carbon), sulfur, SiO2 and Ash. Higher the carbon content and degree of
graphitization (high crystalline) the better is lubricity. However, an impurity like SiO2, ash
has detrimental effect on the functional surfaces.
Synthetic graphite is a high temperature sintered product and is characterized by its high
purity of carbon (99.5-99.9%). The primary grade synthetic graphite can approach the good
lubricity of quality natural graphite and has dark gray to black appearance. Typically
manufactured from calcined petroleum cokes and graphitized at temperatures above 2700o
C, these materials offer high purity and excellent lubrication. Typically grain sizes are
above 15 microns.
Choice of grain size of graphite block is dependent upon functional surface roughness.
Large particles best perform on relative rough surfaces while finer particle on relative
smooth surface.
Figure b
Thus, proper graphite lubrication is mandatory for smooth running and longevity of rolling
surfaces.
We request your comment on the above topic.
ADVANTAGES AT A GLANCE
----·/.
REDUCED \'YEAR ANO TEAR OF" COMPRESSOR COMPONENTS
e-mail: [email protected]
Our services:
5. Repair supervision
6. Erection supervision
-
Allan Smith Team
Immediate correction: